Next step was to fabricate an upper baggage door. This proved to be a much more time consuming process than I had thought it would be. The process was a lot harder because I didn’t have any drawings in the 2+2 plans; the design was from scratch. I did have a few pictures from numerous Super Cubs, but they were very different from one aircraft to another.
First step was to frame out the opening. I decided on hinging from the bottom. The frame needed to take into consideration the angle change of the fuselage at the upper stringer. I used 1/4” Birch ply for the frame..
The lower hinge would have nut plates set into the frame. My method is to carve out the area where the nut plate will be inside the frame and attach the nut plate to a strip of plywood. The plywood is then glued to the frame.
Next, the frame was removed and all surfaces were glassed.
Finished frame installed.
Next was to build the door. I used Douglas Fir for the frame of the door. Pieces were cut and fitted in place. Note that I had the hinge in place to establish proper spacing of the door.
Door out for gluing …….
Back in the frame to test fit. Attention to gaps and thicknesses of wood are necessary to make sure everything fits nicely and follows the projected line of the stringers.
Next, I glued 1/16” mahogany plywood to the inside surface of the door. The outside will be covered with fabric.
Test fitting the door ……. again. This time with the hinge attached.
The light colored wood in the middle of the door was an area where I needed to remove some plywood so the door would close nicely against the center support in the opening.
Next, I installed RV locks, one front and one rear.
On the outside of the door, I glued plywood strips so the door would over hang the side fuselage fabric. I’ll be able to put a rubber seal in this area to keep everything dry.
Small stops were added for the latches to close against.
Finished baggage door.
Next step is a monster …. cabin doors.
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